EP2161408B1 - Aubes d'écran thermique réparées pour entretoise d'échappement de turbine et procédés de réparation - Google Patents

Aubes d'écran thermique réparées pour entretoise d'échappement de turbine et procédés de réparation Download PDF

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Publication number
EP2161408B1
EP2161408B1 EP20090250939 EP09250939A EP2161408B1 EP 2161408 B1 EP2161408 B1 EP 2161408B1 EP 20090250939 EP20090250939 EP 20090250939 EP 09250939 A EP09250939 A EP 09250939A EP 2161408 B1 EP2161408 B1 EP 2161408B1
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EP
European Patent Office
Prior art keywords
vane
replacement section
heat treating
damaged portion
minutes
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP20090250939
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German (de)
English (en)
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EP2161408A3 (fr
EP2161408A2 (fr
Inventor
Eric Herbst
Jeffrey D. Melman
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RTX Corp
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United Technologies Corp
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Publication of EP2161408A2 publication Critical patent/EP2161408A2/fr
Publication of EP2161408A3 publication Critical patent/EP2161408A3/fr
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Publication of EP2161408B1 publication Critical patent/EP2161408B1/fr
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005—Repairing methods or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/005—Repairing turbine components, e.g. moving or stationary blades, rotors using only replacement pieces of a particular form
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49229—Prime mover or fluid pump making
    • Y10T29/49236—Fluid pump or compressor making
    • Y10T29/49238—Repairing, converting, servicing or salvaging
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49318—Repairing or disassembling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49718—Repairing
    • Y10T29/49732—Repairing by attaching repair preform, e.g., remaking, restoring, or patching
    • Y10T29/49734—Repairing by attaching repair preform, e.g., remaking, restoring, or patching and removing damaged material

Definitions

  • This disclosure relates to gas turbine engines.
  • this disclosure relates to repaired turbine exhaust strut heat shield vanes and repair methods.
  • An industrial gas turbine generally includes a stationary exhaust duct through which hot combustion gases are flowed before exiting the main engine into a power turbine used to, for example, generate electricity.
  • the exhaust duct commonly includes an inner annular ring forming the inner wall of the gas path and an outer annular ring forming the outer wall of the gas path.
  • Radially extending struts circumferentially distributed about the engine longitudinal axis span the gas path between and connect to the inner and outer annular rings.
  • Each radially extending strut may be surrounded by an airfoil, thereby forming a stationary vane. The vane acts both to direct gas flow through the exhaust duct and to shield the load bearing struts from heat.
  • Hot combustion gases discharging from the turbine into the exhaust duct during engine operation commonly have a residual velocity component in the tangential direction with respect to the gas path.
  • the tangential velocity component of the hot combustion gases is undesirable as it detracts from the useful energy that may be extracted from the gas flow. Converting the tangential velocity to axial velocity increases the axial thrust produced by the engine, which in turn increases engine performance.
  • the tangential velocity component of the gas flow may be redirected axially by the vanes surrounding the struts of the exhaust duct. More specifically, each vane airfoil may be contoured to aerodynamically redirect the flow of gases from a tangential direction to an axial direction.
  • the durability of the turbine exhaust case and its associated load bearing struts depends largely on the material selected for the case. It is generally desirable to select the material of the case struts based on structural versus, for example, thermal properties. Therefore, it is not uncommon to shield the struts by encapsulating them with non-structural vanes that act as heat shields. In this way the exhaust case struts may be formed of a material that exhibits optimal structural properties, but may not be able to withstand the operating temperatures of the engine without the shielding of the vanes.
  • the vanes on the other hand, may be formed of a material that exhibits optimal thermal, and oxidation and corrosion resistance properties, while not necessarily exhibiting high strengths.
  • the turbine exhaust case strut heat shield vanes may experience a loss of material due to a combination of abrasion, exfoliation, oxidation, hot corrosion and some mode of metallurgical attack during engine operation.
  • the material on the vanes may have temperature limits hundreds of degrees above the engine operating temperatures.
  • the damage observed on the vanes may not have structural repercussions, the damage may compromise, to an increasing degree over time, the heat shielding function of the vanes.
  • structural exhaust case components, i.e. the struts which are intended to be protected by the heat shield vanes may also be compromised. For example, there is an increasing risk that the strength properties of the struts will be degraded and that the struts may yield during operation.
  • EP 1605068 A2 discloses a method of homogeneously welding a superalloy which includes preheating the superalloy prior to welding and allowing it to cool prior to welding.
  • a method of repairing a turbine exhaust case strut heat shield vane comprises removing a damaged portion of the vane; solution heat treating the vane; attaching a replacement section to the vane; and relieving local stresses in an attachment area between the replacement section and the vane; wherein attaching a replacement section to the vane comprises welding the replacement section; and wherein welding the replacement section to the vane comprises buttwelding the replacement section; the method further comprising cooling one or more portions of a strut around which the vane is arranged to protect the portions of the strut during welding.
  • FIG. 1 is a partial axial section view of industrial gas turbine 10 including compressor 12, combustor 14, turbine section 16, and exhaust case 18. Although the section view of FIG. 1 shows only one combustor 14, turbine 10 will generally include multiple combustors 14 circumferentially distributed around a turbine main shaft (not shown).
  • Turbine section 16 includes a plurality of rotating blades 20 secured to a rotatable rotor disk 22. A plurality of stationary vanes 24 are each alternately positioned upstream of each of the rotating blades 20. The vanes 24 are dimensioned and configured to guide the working gas over the blades 20.
  • air is drawn in through the compressor 12, where it is compressed and driven towards the combustor 14.
  • the compressed air enters combustor 14 through an air intake. After entering combustor 14, the air is mixed with fuel.
  • Combustor 14 ignites the fuel/air mixture, thereby forming a working gas.
  • the working gas exiting combustor 14 may be at a temperature approximately between 2,500° F and 2,900° F (1,371° C - 1,593° C).
  • the gas expands through turbine 16, being guided by vanes 24 to drive rotating blades 20. As the gas passes through turbine 16, it rotates blades 20 which, in turn, drive disk 22, thereby transmitting usable mechanical work through disk 22 to a main shaft of turbine 10.
  • the remaining portion of useful energy in the working gas exits turbine 16 and passes through exhaust case 18.
  • the working gas will commonly proceed downstream from exhaust case 18 into a power turbine (not shown) attached to industrial turbine 10, which may be used to power, for example, an electrical generator.
  • Industrial gas turbine 10 may also include a cooling system configured to supply a coolant, for example, steam or compressed air, to internally cool blades 20 and vanes 24 and other turbine components.
  • Exhaust case 18 is positioned downstream of the last row of turbine blades 20 shown in FIG. 1 .
  • FIG. 2 is a detail view of exhaust case 18 including a pair of annular rings, such as diffusers 34 and 36, struts 38, and heat shield vanes 40.
  • Diffuser 34 forms the inner wall of the working gas path and diffuser 36 forms the outer wall of the working gas path.
  • Radially extending struts 38 are circumferentially distributed about the engine axis and span the gas path between diffusers 34, 36. Each radially extending strut 38 is surrounded by vane 40. Vanes 40 act both to direct working gas flow through exhaust case 18 and to shield load bearing struts 38 from heat.
  • Vanes 40 shown in FIGS. 1 and 2 may experience a loss of material due to a combination of abrasion, exfoliation, oxidation, hot corrosion and some mode of metallurgical attack during engine operation. Although the damage observed on vanes 40 may not have structural repercussions, the damage may compromise, to an increasing degree over time, the heat shielding function of vanes 40. Vanes 40 may therefore be repaired by embodiments of the exemplary method, such as method 50 illustrated by the flow chart of FIG. 3 . In FIG.
  • method 50 of repairing a strut heat shield vane includes removing a damaged portion of the vane (step 52), solution heat treating the vane (step 54), cooling an exhaust case strut around which the vane is arranged (step 56), attaching a replacement section to the vane (step 58), relieving local stresses in an attachment area between the replacement section and the vane (step 60), and removing material from the attachment area between the replacement section and the vane (step 62).
  • Method 50 includes removing a damaged portion of the vane (step 52).
  • the damaged portion of the vane removed (step 52) may be, for example, a damaged portion of the leading edge of the vane.
  • the leading edge may exhibit thinning, cracking, pitting, crevice corrosion, and even holes penetrating the vane wall.
  • the leading edge of the vane generally experiences higher temperatures and greater oxidation, abrasion, and corrosion than other portions of the vane. Therefore, the leading edge of the vane may be worn to a further extent and more rapidly than other portions of the heat shield vane.
  • the damaged portion of the vane may be removed (step 52) with, for example, a manual die grinder or cutting wheel, or by another equivalent method known in the art.
  • method 50 includes solution heat treating the vane (step 54).
  • Solution heat treatment is a process in which an alloy is heated to a suitable temperature and held at this temperature for a sufficient length of time to allow a desired constituent to enter into solid solution, followed by rapid cooling to hold the constituent in solution.
  • solution heat treating the vane (step 54) may be employed to, for example, improve the weldability of the vane prior to attaching a replacement section to the vane (step 56), while avoiding any detrimental metallurgical affects to the dissimilar alloy of the structural turbine exhaust case strut (discussed in more detail below).
  • thermal loading may degrade the heat shield vane material by causing certain constituents, such as carbides and nitrides, to come out of solution and migrate toward grain boundaries.
  • the out of solution constituents may degrade the thermal and structural properties of the heat shield vane material.
  • Solution heat treating the vane facilitates bringing the constituents, e.g. carbides and nitrides, of the vane material back into solution in the alloy, which generally rejuvenates the material properties and improves weldability by, for example, improving ductility at the weld site.
  • Solution heat treating the vane may include heat treating the vane in a protective atmosphere of Argon, Hydrogen, Helium, or in a vacuum.
  • the vane may be heated at, for example, 1350 +/- 25° F (732 +/- 14° C) for 4 hours +/- 10 minutes and cooled from 1350+/- 25° F (732 +/- 14° C) to 1200 +/- 25° F (650 +/- 14° C) at a rate of 100 +/- 25 F° (56 +/- 14 C °) per 1 hour +/- 10 minutes.
  • the vane may then be held at 1200 +/- 25° F (650 +/- 14° C) for 3 hours +/- 10 minutes. Any convenient cooling rate may be used below 1200° F (650° C).
  • method 50 may include the optional step of cooling an exhaust case strut around which the vane is arranged (step 56).
  • the exhaust case struts are formed of materials that may need to be kept to temperatures well below the operating temperatures of the engine to maintain their strength.
  • An example material used for turbine exhaust cases, including the struts, is INCONEL® alloy 718 Manufactured by Special Metals Corporation of Huntington, West Virginia.
  • INCONEL® alloy 718 is a precipitation-hardenable nickel-chromium alloy also containing significant amounts of iron, niobium, and molybdenum along with lesser amounts of aluminum and titanium.
  • Cooling the exhaust case strut (step 56) may include, for example, directing pressurized air against the strut on the exhaust case.
  • Method 50 also includes attaching a replacement section to the vane (step 58).
  • Methods of repairing strut heat shield vanes facilitate providing repeatable processes for repairing, as opposed to completely replacing, worn heat shield vanes.
  • the exemplary methods facilitate improving the operational performance of the vane by substituting newer, higher performance materials during the repair as compared to known repair methods.
  • the damaged portion of the vane removed (step 52) may be fabricated from a first material and the replacement section attached to the vane (step 58) may be fabricated from a second material.
  • the first and second materials may be identical, i.e., simply replacing the damaged portion with a substantially equivalent replacement section.
  • the first and second materials may be different from one another.
  • the first material of the damaged portion may include a nickel-chromium-molybdenum alloy, such as INCONEL® alloy 625 manufactured by Special Metals Corporation of Huntington, West Virginia
  • the second material of the replacement section may include a nickel-chromium-iron-molybdenum, such as HASTELLOY® X manufactured by Haynes International, Inc. of Kokomo, Indiana.
  • HASTELLOY® X alloy possesses a combination of oxidation resistance, fabricability and high-temperature strength. It has also been found to be resistant to stress-corrosion cracking and exhibits good ductility after prolonged exposure at temperatures of, for example, 1200, 1400, and 1600°F (650, 760, and 870°C respectively).
  • Attaching a replacement section to the vane may include, for example, butt-welding the replacement section.
  • Butt-welding the replacement section to the strut heat shield vane may include manual gas tungsten arc or manual plasma-transferred arc welding with INCONEL® 625 or HASTELLOY® X weld filler wire. Argon purge back ups may be employed during welding to maximize the weld quality.
  • method 50 includes relieving local stresses in an attachment area between the replacement section and the vane (step 60).
  • Relieving local stresses in an attachment area between the replacement section and the vane (step 60) may include, for example, heat treating the vane.
  • the weld site i.e. attachment area
  • the HAZ commonly includes detrimental effects, such as grain growth, which may make the vane alloy more brittle and cause cracking. Additionally, the rapid cooling of the hot weld material places the material at the weld site in tension, i.e.
  • heat treating the vane after attaching the replacement section (step 58) may act to reduce grain size in the HAZ, as well as relieve residual stresses created during welding.
  • the stress relief heat treatment conducted after attaching the replacement section (step 58) may employ a similar heat treatment schedule as described above with reference to the solution heat treating (step 54).
  • Method 50 may also include removing material from the attachment area between the replacement section and the vane (step 62). Attaching the replacement section to the vane (step 58) may leave excess material in an attachment area between the replacement section and the vane. For example, in the case the replacement section is welded to the vane, weld beads may protrude between approximately 0.020 - 0.030 inches (0.508 - 0.762 mm respectively) above the surrounding surfaces of the vane and therefore may necessitate blending to match the contoured geometry of the vane.
  • Removing material from the welded connection may include one or more of grinding, polishing, and sanding the welded connection. For example, rotary hand tools and aluminum oxide impregnated grinding wheels may be employed to manually blend the weld areas with the adjacent surfaces of the vane.
  • the repaired strut heat shield vane may be inspected. Inspecting the vane may include, for example, wetting the vane weld areas with high sensitivity fluorescent fluid, and visually inspecting the weld areas under an ultraviolet light source. After inspecting the weld areas, the cross-sectional shape and size of the replacement section may be measured by, for example, using a profile gauge to ensure the replacement section complies with the original specifications of the vane.
  • FIGS. 4A and 4B are detail views of strut heat shield vane 40 repaired by method 50 illustrated in FIG. 3 .
  • Heat shield vane 40 surrounds strut 38 between diffusers 34 and 36.
  • Vane 40 includes leading edge 64 and replacement section 64a.
  • leading edge 64 may have experienced a loss of material due to a combination of abrasion, oxidation and some mode of metallurgical attack during engine operation. The damaged portion of vane 40 has therefore been removed in the region of leading edge 64.
  • Replacement section 64a has then been attached to vane 40 by, for example, welding replacement section 64a to vane 40.
  • the exemplary methods of repairing strut heat shield vanes discussed above facilitate providing repeatable processes for repairing, as opposed to completely replacing, warn or damaged heat shield vanes.
  • improving the operational performance of the vane by substituting newer, higher performance materials during the repair may be facilitated.
  • the damaged leading edge of the vane may be fabricated from a nickel alloy, such as INCONEL® 625, while the replacement section attached to the vane in the exemplary methods may be formed of a newer generation, higher performance nickel alloy, such as HASTELLOY® X.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Claims (11)

  1. Procédé (50) de réparation d'une aube d'écran thermique d'entretoise de buse d'échappement de turbine (40), le procédé comprenant les étapes consistant à :
    retirer (52) une portion endommagée de l'aube ;
    traiter l'aube à chaud en solution (54) ;
    fixer (58) une section de remplacement à l'aube ; et
    libérer les contraintes locales (60) dans une zone de fixation entre la section de remplacement et l'aube ;
    dans lequel la fixation d'une section de remplacement à l'aube comprend le soudage de la section de remplacement ; et
    dans lequel le soudage de la section de remplacement à l'aube comprend le soudage bout à bout de la section de remplacement ; le procédé comprenant en outre :
    le refroidissement d'une ou plusieurs portions d'une entretoise autour de laquelle l'aube est aménagée pour protéger les portions de l'entretoise au cours du soudage.
  2. Procédé selon la revendication 1, dans lequel le retrait d'une portion endommagée de l'aube comprend au moins l'un ou l'autre d'un meulage et d'un découpage à l'emporte-pièce.
  3. Procédé selon la revendication 1 ou la revendication 2, dans lequel la portion endommagée comprend un premier matériau et la section de remplacement comprend un second matériau ; et dans lequel le premier matériau et le second matériau sont sensiblement les mêmes ou, en variante, dans lequel le premier matériau et le second matériau sont différents l'un de l'autre.
  4. Procédé selon la revendication 3, dans lequel le premier matériau comprend un alliage de nickel-chrome-molybdène et le second matériau comprend un alliage de nickel-chrome-fer-molybdène.
  5. Procédé selon la revendication 1, 2, 3 ou 4, dans lequel le retrait d'une portion endommagée de l'aube comprend le retrait d'une portion endommagée d'un bord d'attaque de l'aube.
  6. Procédé selon la revendication 1, 2, 3, 4 ou 5, dans lequel le traitement à chaud en solution de l'aube comprend le traitement à chaud de l'aube dans une atmosphère protectrice d'au moins l'une ou l'autre d'argon, d'hydrogène et d'hélium ; en variante, dans lequel le traitement à chaud en solution de l'aube comprend le traitement à chaud dans un vide.
  7. Procédé selon l'une quelconque des revendications précédentes, dans lequel le traitement à chaud en solution de l'aube comprend :
    le chauffage de l'aube à 732 +/- 14 °C (1350 +/-25 °F) pendant 4 heures +/- 10 minutes ;
    le refroidissement de l'aube de 732 +/- 14 °C (1350 +/- 25 °F) à 650 +/- 14 °C (1200 +/- 25 °F) à raison de 56 +/- 14 °C (100 +/- 25 °F) pendant 1 heure +/- 10 minutes ; et
    le chauffage de l'aube à 650 +/- 14 °C (1200 +/-25 °F) pendant 3 heures +/- 10 minutes.
  8. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre le retrait (62) de matériau d'une liaison soudée entre la section de remplacement et l'aube.
  9. Procédé selon l'une quelconque des revendications précédentes, dans lequel la libération des contraintes locales dans une zone de fixation entre la section de remplacement et l'aube comprend le traitement à chaud de l'aube dans une atmosphère protectrice d'au moins l'une ou l'autre d'argon, d'hydrogène et d'hélium ; en variante, dans lequel la libération des contraintes locales dans une zone de fixation entre la section de remplacement et l'aube comprend le traitement à chaud de l'aube dans un vide.
  10. Procédé selon l'une quelconque des revendications précédentes, dans lequel la libération des contraintes locales dans une zone de fixation entre la section de remplacement et l'aube comprend :
    le chauffage de l'aube à 732 +/- 14 °C (1350 +/-25 °F) pendant 4 heures +/- 10 minutes ;
    le refroidissement de l'aube de 732 +/- 14 °C (1350 +/- 25 °F) à 650 +/- 14 °C (1200 +/- 25 °F) à raison de 56 +/- 14 °C (100 +/- 25 °F) pendant 1 heure +/- 10 minutes ; et
    le chauffage de l'aube à 650 +/- 14 °C (1200 +/-25 °F) pendant 3 heures +/- 10 minutes.
  11. Procédé selon l'une quelconque des revendications précédentes, comprenant en outre (56) le refroidissement de l'entretoise de buse de d'échappement au cours du traitement à chaud en solution.
EP20090250939 2008-09-05 2009-03-30 Aubes d'écran thermique réparées pour entretoise d'échappement de turbine et procédés de réparation Ceased EP2161408B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US12/205,257 US8083465B2 (en) 2008-09-05 2008-09-05 Repaired turbine exhaust strut heat shield vanes and repair methods

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EP2161408A2 EP2161408A2 (fr) 2010-03-10
EP2161408A3 EP2161408A3 (fr) 2013-11-06
EP2161408B1 true EP2161408B1 (fr) 2015-04-22

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US20100061846A1 (en) 2010-03-11
EP2161408A3 (fr) 2013-11-06
US8083465B2 (en) 2011-12-27
EP2161408A2 (fr) 2010-03-10

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